Refractory material and method of making



Patented Sept. 4, 1951 UNITED STATES PATENT GEE! REFRACTORY MATERIAL Ann METHOD on MAKING,

NoDrawing. Application November 3; 1948 Serial No. 58,159

14 Claims.

This invention relates toplastic compositionsand the method of making the same, and especially to those having 'fire and'hea't resistant properties.

More particularly, the invention. relates to re! fractory material having. azircon base.

Refractorieshave.heretofore been made from various materials vincluding.zircon (Z'r'Si'O4). The. latter has becomejof increasing importance be.- cause of its superior refractory qualities including that of an extremely high melting point, strength at high temperatures'and thelike. Certain disadvantages.havelimitecl th use, however, including that of. an undesirably high coefficient of expansion.

It is an object of the presentinvention to pro: vide a refractory, material possessing superior qualities including that of the ability to withstand" high temperatures, thermal shock, abrasive or erosive action and to which slag does not readily adhere.

The present invention is directed to refractory material adapted for application in plastic form as a wash or lining, or which is adapted" to be formed into refractory bricks and the like.

In the past, refractory material when exposed to relatively high temperatures in metal producing furnaces was burned or eroded from the heat and the materials within the furnace to such an extent that relatively thick furnace linings were required. These had to be replaced often which necessitated the shutting down of the furnace and substantial additional expenditure.

Constructed of material in accordance with the present invention a furnacelining is relatively long-lasting, and considerable expense is saved because of the less frequent necessity of replacing the lining. Considerable commercial success has madQ ndm high-pressure and in re1ative1y=1ar e units, a qual ty-in' which oth rrcfrac r shavebeenzlacking.

, .One of. the. significant. advantages. of. the: ma

' tar-ialaof. the present inventionjszthat: it has. rela:

tively. low coefiicientsof.expansionand contilac:

tion, thus. reducing the stresses which would otherwise be setup in the structure and particuto a maximum Qt of t is invcnt eeshq peraturesfromfii ilhr rhama-teri p it .az:l w llada ts r us refracto linin -0,1- asawash 9 a? ing over the linings in nearly all typesof fur ac s including-. e1ectrica1;,h1astz-cano a,- p niarine; railroad or. other-boilers; nheati eq ip; menta of any. kinda whether: gas,:. coke; 9.1L 0 fired... It: may. also: be used with ferrous or. ferrous met'alz producing. opera ions 9 9 91 dustrialzoncommercial-use; The material. is: adaptegliforuuse: in the-fluid: stateas. a1washr tozbesplastfir d or sprfi rd 1D 1, other refractory linings. In solid form it is es:- peciallyiwell adapted to he-imade'into b r blocks of various sizes; and? shapes forxuse a 30 refractory: In: carrying out the invention Mari ous ranges ofiproportions :of: the ingredients: mam be used 1 but it has been found: that the propertions set forth in the following example'sareuparc-v ticularly well adaptedifora thetpiirposes-.-statedi Em .rls l- To produce a' material for application-in or plastic form the following 'proportions of the n r die s Qfihe. n r re QI QF EQ; i 'b r 40 understood. that? re ble deviation may be @rcseflrwsisli? Zircon sand; 10

tsetse 3 Emample II For use in brick or block form substantially the following proportions of ingredients have been found to be preferred:

Per cent by weight Zircon sa 27 Ground zircon sand (200 mesh-6 mesh) '70 Crushed silica rock (ganister preferred) 2 Plastic fire clay Bentonite t =1 Small amoun $315313 silicate of soda} according to fluidity desired;

the actual possible maximum and minimum limits for obtaining useful results:

v Per cent by weight Zircon sand 20-60 Ground zircon sand (200mesh-6 mesh) 40-80 Crushed silica rock (ganister preferred) 220 Plastic fire clay 0.5-15

Bentonite 0.5-10

Sodium silicate (liquid preferred) 0.5-

Water Amount accordin to fluidity desired and intended use.

oughly mixed by suitable mechanical means. 1

Although the order of combining the ingredients is not believed to be critical it has been found that the preferred order of adding the ingredients is as follows: Liquid (silicate and water),

ganister, ground zircon sand, zircon sand, plastic.

fire clay, bentonite.

When refractory brick or block is to be made. the proper mixture is formed under ten tons or -more pressure into the desired shape and size following which it is air dried at about 212 F., and finally baked for approximately an hour at from 2850 F. to 3100 F.

The invention has been described in detail for the purpose of illustration but it will be obvious that numerous modifications and variations may be resorted to without departing from the spirit of the invention.

What is claimed is:

1. A plastic refractory lining for a furnace comprising, in approximately the following proportions by weight, zircon sand 10%, ground zircon 66%%, crushed silica rock 1 of a selected binder from the group consisting of plastic fire clay, ball clay," and kaolin, and bentonite 1%%, together with sodium silicate and water in an amount according to the fluidity desired.

2. A plastic refractory lining for a furnace comprising, in approximately the following proportions by weight, zircon sand 76 silica rock 20%, bentonite 1%%, and 1%% of a binder se- 4 lected from the group consisting of plastic fire clay, ball clay, and kaolin, together with sodium silicate and water in an amount according to the fluidity desired.

3. A plastic refractory lining for a furnace comprising, in approximately the following proportions by weight, zircon sand 76 silica rock 20%, bentonite 1 /3 and plastic fire clay 1 together with sodium silicate and water in an amount according to the fluidity desired.

4. A refractory composition which comprises; in approximately the following proportions by Weight, zircon sand 27%, ground zircon 70%, crushed silica rock 2%, bentonite and of a binder selected from the group consisting of plastic fire clay, ball clay, and kaolin, together with sodium silicate and water in an amount according to the fluidity desired.

5. A refractory composition which comprises, in approximately the following proportions by weight, zircon sand 79%, silica rock 2%, bentonite and plastic fire clay A together with sodium silicate and water in an amount according to the fluidity desired.

6. A refractory composition which comprises, in approximately the following proportions by weight, zircon sand 96%, silica rock 2%, plastic fire clay 1%, bentonite 1%, together with sodium silicate and water in an amount according to the fluidity desired.

7. A refractory composition which comprises, in approximately the following proportions by weight, zircon sand 96%, silica rock 2%, bentonite 1%, a binder selected from the group consisting of plastic fire clay, ball clay, or kaolin 1%, together with sodium silicate and water in an amount according to the fluidity desired.

8. The method of making refractory brick comprising mixing together zircon sand 10%, ground zircon se 3%, silica rock 20%, bentonite l a binder selected from the group consisting of plastic fire clay, ball clay, and kaolin 1 and liquid sodium silicate, forming the mixture under pressure into unit shapes, heating to approximately 212 F. and holding until the unit shapes are substantially dry, and baking at a temperature in the range of 2850" F. to 3100 F.

9'. The method of making a refractory brick comprising mixing together zircon sand '76%%, silica rock 20%, bentonite l%%, plastic fire clay 1% and sodium silicate and water, forming the mixture under pressure into unit shapes, heating to approximately 212 F. and holding until the unit shapes are substantially dry, and baking at a temperature in the range of 2850 F. to 3100 F.

10. Theimethod of making a refractory brick comprising mixing together zircon sand 76 silica rock 20%, bentonite 1 a binder selected from the group consisting of plastic fire clay, ball clay, or kaolin l%% sodium silicate and water, forming the mixture under pressure into unit shapes, heating to approximately 212 F. and holding until the unit shapes are substantially dry, and baking at a'temperature in the range of 2850" to 3100 F.

11. A refractory composition comprising in approximately the following proportions by weight, zircon sand 20% to 60%, ground zircon 40% to silica rock 2% to 20%, plastic fire clay 0.5% to 15%, bentonite 0.5% to 10%, sodium silicate 0.5% to 15%. and water in an amount according to the fluidity desired.

12. A refractory composition comprising, in approximately the following proportions by weight, zircon sand 20% to 60%, ground zircon 40% to 80%, silica rock 2% to 20%, a binder selected from the group consisting of plastic fire clay, ball clay, and kaolin 0.5% to 15%, bentonite 0.5% to sodium silicate 0.5% to and water in an amount according to the fluidity desired.

13. A refractory composition comprising, in approximately the following proportions by weight, zircon sand to ground zircon 40% to silica rock 2% to 20%, an organic binder selected from the group consisting of goulac and glutrin 0.5% to 15%, bentonite 0.5%

to 10%, sodium silicate 0.5% to 15%, and water in an amount according to the fluidity desired.

14. The method of making a refractory brick comprising mixing together zircon sand 97%, silica rock 2%, bentonite plastic fire clay A;%, sodium silicate and water, forming the mixture under pressure into unit shapes, heating to approximately 212 F, and holding until the unit shapes are substantially dry, and baking at 10 a temperature in the range of 2850 F. to 3100 F.

CHESTER C. TEASEL.

No references cited. 

1. A PLASTIC REFRACTORY LINING FOR A FURNACE COMPRISING, IN APPROXIMATELY THE FOLLOWING PROPORTIONS BY WEIGHT, ZIRCON SAND 10%. GROUND ZIRCON 662/3%, CRUSHED SILICA ROCK 20%, 12/3% OF A SELECTED BINDER FROM THE GROUP CONSISTING OF PLASTIC FIRE CLAY, BALL CLAY, AND KAOLIN, AND BENTONITE 12/3%, TOGETHER WITH SODIUM SILICATE AND WATER IN AN AMOUNT ACCORDING TO THE FLUIDITY DESIRED. 